This arrangement raises a LOT of red flags. Here's a breakdown of the potential issues, categorized for clarity

I. Safety and Electrical Issues:
Submersion Hazard

This is the biggest and most dangerous problem. Regularly submerging energized electrical components (modules, connectors, wiring) is a MAJOR electrocution hazard. Water is a conductor, especially dirty water from the ground. Even low voltage DC can be dangerous in wet conditions.

Connectors are NOT designed for continuous submersion. They are often IP67 or IP68 rated for temporary submersion, but that's not the same as constant, prolonged exposure. Water will ingress, leading to corrosion, short circuits, and ground faults. Module Degradation

Water permeation through the module's encapsulation can lead to delamination, corrosion of internal components, and reduction in performance. This can also lead to premature module failure.

Ground Faults

Water can create a path to ground, triggering ground faults and potentially damaging the system. Ground fault protection devices (GFP) are crucial, but may not be sufficient to prevent all problems.

Wildlife

Wet soil and water attract animals (insects, rodents, amphibians). Animals can chew on wiring or create paths to ground, exacerbating safety concerns and damaging the system.

Electromagnetic Interference (EMI)

High-current DC circuits can radiate EMI. Being in direct contact with the ground may make the system more sensitive to EMI and also lead to more EMI affecting surrounding objects.

Lightning Protection

This setup will increase the likelihood of lightning strikes and the potential for damage, since the modules are in contact with the earth. A proper grounding system is vital, but grounding may prove to be more dangerous for the reasons stated above.

Electrical Code Violations

This design is almost certainly in violation of local and national electrical codes. Proper clearances and insulation are required for electrical equipment, and this setup likely fails to meet those requirements.

II. Performance and Reliability Issues



Soiling and Shading



Dirt and Mud Accumulation

Laying modules flat on the ground guarantees they will quickly accumulate dirt, mud, and debris. Automatic cleaning systems might help, but they are unlikely to be perfectly effective, especially with caked-on mud.

Shading

Even small amounts of shading on a portion of a module can significantly reduce its output, due to bypass diodes. Weeds, grass, or even fallen leaves can cause shading.

Module Degradation (Beyond Water Intrusion)



Temperature

Modules laid flat on the ground can experience higher operating temperatures than elevated modules due to lack of ventilation. This can accelerate degradation and reduce efficiency.

Thermal Cycling

Temperature fluctuations will cause expansion and contraction of the module materials, which can weaken bonds and lead to failures.

Mechanical Stress



Uneven Support

The ground is not perfectly flat, so the modules may be subject to uneven pressure and stress, potentially leading to cracking or other damage.

Weight Distribution

Concrete blocks and aircraft cable will create point loads on the modules, further exacerbating stress and the potential for cell cracking.

Vegetation Growth

Weeds, grass, and other plants will grow up and around the modules, competing for sunlight, retaining moisture, and potentially damaging the modules.

Connector Corrosion

Even if the connectors are rated as IP67 or IP68, they can corrode when constantly submerged in water.

Snow Accumulation

Depending on the location, snow accumulation can completely bury the modules, blocking sunlight and potentially adding significant weight.

III. Economic and Practical Issues



Increased Maintenance

The issues listed above will lead to significantly increased maintenance requirements: More frequent cleaning. Repairing or replacing damaged modules, connectors, and wiring. Weed control.

Reduced Lifespan

The harsh operating conditions will likely shorten the lifespan of the modules and other components, reducing the overall return on investment.

Increased Insurance Costs

The high risk of electrical hazards, damage, and reduced performance will likely lead to higher insurance premiums, or even difficulty obtaining insurance.

Land Use and Environmental Impact

The design would severely restrict the land use of the PV site. Any natural habitats under the panels would die. The constant need for vegetation control would have environmental consequences.

Module Selection

Requires specific modules designed to withstand physical contact with the earth.

IV. Specific Concerns about the Holding Method (Aircraft Cable and Concrete Blocks)



Module Damage

Concrete blocks directly on the module surface are a huge risk for scratching and cracking the glass. Even if the blocks are placed on the frame, they may apply too much stress.

Aircraft Cable Wear

Aircraft cable can fray and wear, and the modules could be lifted off the ground in high winds. It would require constant inspection.

Ground Shifting

Ground settling or erosion could loosen the cables and create uneven pressure on the modules.

Difficult Access

The aircraft cables could also pose a tripping hazard.

In Summary

While the idea of reducing racking costs and maximizing ground coverage is appealing, this implementation is fraught with problems. The risks to safety, performance, and reliability are simply too high to justify the potential cost savings. This design is likely to be unsafe, unreliable, and ultimately uneconomical.

Recommendations



Abandon this approach. Investigate other cost-effective racking solutions that provide proper module support, ventilation, and protection from environmental hazards. Consider standard fixed-tilt systems or newer, lower-cost racking designs that still meet safety and performance standards.* Consult with experienced solar PV engineers and installers to develop a safe, reliable, and economically viable solar power system. Flag for review